NEMA Standards Publication No. WC 71-1999 ICEA Publication No. S-96-659-1999 Standard for Nonshielded Cables Rated 2001-5000 Volts for use in the Distribution of Electric Energy Published by National Electrical Manufacturers Association 1300 North 17th Street, Suite 1847 Rosslyn, Virginia 22209 Copyright 1999 by the National Electrical Manufacturers Association and the Insulated Cable Engineers Association, Incorporated (ICEA). All rights including translation into other languages, reserved under the Universal Copyright Convention, the Berne Convention or the Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions.
NEMA STANDARDS PUBLICATION No. WC-71-1999 ICEA PUBLICATION No. S-96-659-1999 STANDARD FOR NONSHIELDED CABLES RATED 2001-5000 VOLTS FOR USE IN THE DISTRIBUTION OF ELECTRIC ENERGY INSULATED CABLE ENGINEERS ASSOCIATION April 2, 1998 Copyright 1999 by the National Electrical Manufacturers Association and the Insulated Cable Engineers Association, Incorporated (ICEA). All rights including translation into other languages, reserved under the Universal Copyright Convention, the Berne Convention for the Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions.
Page i FOREWORD This Standards Publication for Nonshielded Cables Rated 2001-5000 Volts was developed by the Insulated Cable Engineers Association, Incorporated (ICEA) and was approved by the National Electrical Manufacturers Association (NEMA). ICEA/NEMA Standards are adopted in the public interest and are designed to eliminate misunderstandings between the manufacturers and the user and to assist the user in selecting and obtaining the proper product for his or her particular need. The user of this Standards Publication is cautioned to observe any health or safety regulations and rules relative to the use of cable made in conformity with this Standard. Requests for interpretation of this Standard must be submitted in writing to: Insulated Cable Engineers Association, Inc. P.O. Box 440 South Yarmouth, MA 02664 An official interpretation will be made by the Association. Suggestions for improvement gained in the use of this publication will be welcomed by the Association.
Page ii TABLE OF CONTENTS* Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 General Conductors Stress Control Layer (Conductor Shield) Insulation Coverings Assembly Testing and Test Methods Construction of Specific Types Appendices * A more detailed table of contents follows.
Page iii TABLE OF CONTENTS PART 1 GENERAL...1 1.1 SCOPE...1 1.2 INFORMATION TO BE SUPPLIED BY PURCHASER...1 1.2.1 Characteristics of System on Which Cable is to be Used... 2 1.2.2 Quantities and Description of Cable... 2 PART 2 CONDUCTORS... 3 2.0 GENERAL... 3 2.1 PHYSICAL AND ELECTRICAL PROPERTIES... 3 2.1.1 Copper Conductors... 3 2.1.2 Aluminum Conductors... 3 2.2 OPTIONAL SEALANT FOR STRANDED CONDUCTORS... 4 2.3 CONDUCTOR SIZE UNITS... 4 2.4 CONDUCTOR DC RESISTANCE... 4 2.4.1 Direct Measurement of dc Resistance... 4 2.4.2 Calculation of dc Resistance... 4 2.5 CONDUCTOR DIAMETER... 5 PART 3 STRESS CONTROL LAYER (CONDUCTOR SHIELD)... 11 3.0 GENERAL... 11 3.1 MATERIAL AND THICKNESS... 11 3.2 PHYSICAL REQUIREMENTS... 11 3.3 ELECTRICAL REQUIREMENTS... 11
Page iv PART 4 INSULATION... 13 4.1 INSULATION MATERIALS... 13 4.2 INSULATION LEVELS... 13 4.3 INSULATION AND JACKET THICKNESSES... 14 4.4 INSULATION REQUIREMENTS... 16 4.4.1 Voltage Tests... 16 4.4.2 Insulation Resistance... 16 4.4.4 Other Requirements... 16 PART 5 COVERINGS... 21 5.1 JACKETS... 21 5.1.1 Cross-linked and Thermoplastic jackets... 21 5.1.2 Repairs... 21 5.1.3 Neoprene, Heavy-duty Black (CR_HD)... 21 5.1.4 Neoprene, General Purpose (CR-GP)... 21 5.1.5 Polyvinyl Chloride (PVC)... 21 5.1.6 Low and Linear Low Density Polyethylene (LDPE & LLDPE)... 21 5.1.7 Medium Density Polyethylene, Black (MDPE)... 21 5.1.8 High Density Polyethylene (HDPE)... 22 5.1.9 Nitrile-butadiene/Polyvinyl-chloride, Heavy Duty (NB/PVC-HD)... 22 5.1.10 Nitrile-butadiene/Polyvinyl-chloride, General Purpose (NB/PVC-GP)... 22 5.1.11 Chlorosulfonated Polyethylene, Heavy Duty (CSPE-HD)... 22 5.1.12 Chlorinated Polyethylene, Thermoplastic (CPE-TP)... 22 5.1.13 Chlorinated Polyethylene, Cross-Linked, Heavy Duty (CPE-XL-HD)... 22 5.1.14 Optional Requirements... 22 5.1.15 Separator Under Jacket... 22 5.1.16 Jacket Thickness... 25 5.2 METALLIC AND ASSOCIATED COVERINGS... 25 5.2.1 General... 25 5.2.2 Divisions... 27 5.3 DIVISION I... 27 5.3.1 Metallic Sheaths... 27 5.3.2 Flat Steel Tape Armor... 29 5.3.3 Interlocked Metal Tape Armor... 31 5.3.4 Continuously Corrugated Metal Armor... 32 5.3.5 Galvanized Steel Wire Armor For Submarine Cables... 32 5.3.6 Bedding Over Cable Cores To Be Metallic Armored... 35 5.3.7 Outer Servings... 36 5.3.8 Cross-linked Jackets Over Metallic Sheaths and Armors... 36 5.3.9 Thermoplastic Jackets Over Metallic Sheaths and Armors... 38
Page v 5.4 DIVISION II... 39 5.4.1 Borehole Cable (Suspended at One End Only)... 39 5.4.2 Dredge Cable... 39 5.4.3 Shaft Cable... 40 5.4.4 Vertical Riser Cable... 41 5.5 DIVISION III... 41 5.5.1 Buried Land Cables... 41 PART 6 ASSEMBLY, FILLERS, GROUNDING CONDUCTORS, AND IDENTIFICATION... 43 6.1 ASSEMBLY OF MULTIPLE-CONDUCTOR CABLES... 43 6.1.1 Multiple Conductor Round Cables With An Overall Covering... 43 6.1.2 Flat Twin Cables With Overall Covering... 44 6.1.3 Multiple Conductor Cables Without An Overall Covering... 44 6.2 FILLERS... 44 6.3 GROUNDING CONDUCTORS... 44 6.4 CONDUCTOR IDENTIFICATION... 45 PART 7 TESTING AND TEST METHODS... 47 7.1 GENERAL... 47 7.1.1 Testing and Sampling Frequency... 47 7.1.2 Test Methods... 47 7.1.3 Number of Test Specimens From Samples... 47 7.2 THICKNESS MEASUREMENTS... 49 7.2.1 Beddings and Servings... 49 7.2.2 Other Components... 49 7.3 SAMPLES AND SPECIMENS FOR PHYSICAL AND AGING TESTS... 49 7.3.1 General... 49 7.3.2 Sampling... 49 7.3.3 Size of Test Specimens... 49 7.3.4 Specimens With Removable Jackets... 50 7.3.5 Specimens With Non-Removable Jackets... 50 7.3.6 Specimen Surface Irregularities... 50 7.3.7 Specimens for The Aging Tests... 51 7.3.8 Calculation of Area of Test Specimens... 51 7.4 TENSILE, ELONGATION AND SET TEST PROCEDURES... 52 7.4.1 Test Specimens, Machine, and Temperature... 52 7.4.2 Tensile Strength Test... 52 7.4.3 Elongation Test... 52 7.4.4 Tensile Stress Test... 52 7.4.5 Set Test... 52
Page vi 7.5 AGING TESTS... 52 7.5.1 Air Oven Aging Test... 53 7.5.2 Oil Immersion Test... 53 7.5.3 Hot Creep Test... 53 7.6 HEAT SHOCK AND ENVIRONMENTAL TESTS... 53 7.6.1 Heat Shock Test... 53 7.6.2 Environmental Stress Cracking Test... 54 7.6.3 Ozone Resistance Test... 54 7.6.4 Sunlight Resistance Test... 54 7.7 VOLUME RESISTIVITY, COLD-BEND, FLEXIBILITY, AND JACKET TIGHTNESS TESTS... 54 7.7.1 Volume Resistivity Test (Conductor Shield)... 54 7.7.2 Cold-Bend Test... 55 7.7.3 Flexibility Test for Continuously Corrugated Armor... 55 7.7.4 Tightness of Polyethylene Jacket to Sheath Test... 55 7.8 TRAY CABLE FLAME TEST... 55 7.9 ELECTRICAL ACCELERATED WATER ABSORPTION TEST (EM-60)... 56 7.10 U-BEND DISCHARGE RESISTANCE TESTS... 56 7.10.1 Conditioning of Samples Prior to Testing... 56 7.10.2 Bending Mandrel Diameters... 56 7.10.3 Test Voltage and Time... 56 7.11 ELECTRICAL TESTS ON COMPLETED CABLES... 57 7.11.1 Voltage Tests... 57 7.11.2 Insulation Resistance Test... 57 7.12 RETESTS... 58 7.12.1 Physical and Aging Properties and Thickness... 58 7.12.2 Other Tests... 58 PART 8 PART 9 CONSTRUCTION OF SPECIFIC TYPES... 59 8.1 PREASSEMBLED AERIAL CABLES... 59 8.1.1 Scope... 59 8.1.2 Construction... 59 APPENDICES... 61 APPENDIX A... 61 NEMA, ICEA, AND ASTM STANDARDS... 61 APPENDIX B... 64 DEFINITIONS OF MAXIMUM TEMPERATURES OF INSULATED CABLE CONDUCTORS... 64
Page vii APPENDIX C... 65 EMERGENCY OVERLOADS... 65 APPENDIX D... 66 ABBREVIATIONS AND SYMBOLS... 66 APPENDIX E... 67 REPRESENTATIVE TENSILE STRENGTH AND ELONGATION OF NONMAGNETIC METALS... 67 APPENDIX F... 68 RECOMMENDED BENDING RADII AND INSTALLATION TEMPERATURES FOR CABLES... 68 APPENDIX G... 70 ADDITIONAL CONDUCTOR INFORMATION... 70
Page 1 PART 1 GENERAL 1.0 SCOPE This standard applies to materials, constructions, and testing of 2001 through 5000 volt nonshielded power cables having insulations of thermoplastic polyethylene, cross-linked polyethylene or crosslinked rubber, of the types shown in Part 4. The insulation shall be either covered with a discharge resistant jacket or shall be a discharge-resistant material without a jacket. Discharge resistant insulations and jackets shall comply with the applicable surface resistivity, U-bend discharge, and track-resistance requirements of Parts 4 and 5. The nonshielded cables described in this standard are intended for use for the transmission and distribution of electrical energy in normal conditions of service in indoor, outdoor, aerial, underground, or submarine installations within the application limits shown in Table 4-4 and in 5.2.1. They are not intended for portable use applications. 1.1 GENERAL INFORMATION This standard covers the requirements for conductors, insulations, jackets, and protective coverings as well as general construction and dimensional details common to most standard nonshielded types of wires and cables rated 2001-5000 volts. Insulation thicknesses are designated in terms of cable insulation levels defined in Part 4. See Part 7 for test procedures not elsewhere referenced. Requirements of a referenced ASTM standard shall be determined in accordance with the procedure or method designated in the referenced ASTM standard unless otherwise specified in this standard. See Appendix A in Part 9 for complete titles and dates of ICEA publications, NEMA publications, and ASTM Standards to which reference is made in this publication. In classifying jackets and sheaths in this standard, the term "jacket" refers to a continuous nonmetallic covering and "sheath" to a continuous smooth metallic covering. In this standard, units are expressed in the English system. For information only, their approximate metric equivalents are included. Abbreviations and symbols used in the standard are defined in Appendix D. 1.2 INFORMATION TO BE SUPPLIED BY PURCHASER When requesting proposals from cable manufacturers, the prospective purchaser should furnish the following information: